Producing ceramic moulds or cores
URN: SEMMPF208
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
30 Mar 2020
Overview
| This standard identifies the competences you need to produce ceramic moulds or cores, using manual and semi- mechanised methods, in accordance with approved procedures. You will be required to select the appropriate equipment to use, based on the type and size of the moulds or cores, the moulding or coremaking method employed and the metal to be cast. Moulding or coremaking will take place, using recognised techniques, in jobbing and semi- mechanised foundries. You will be expected to produce the moulds/cores using chemically bonded refractory materials. The completed moulds or cores will be air/gas torch dried, followed by stoving, to develop a ceramic mould or core. You will be expected to prepare the mainly resin or metal pattern equipment and to insert any preformed parts to aid casting definition or the stripping properties required. Using pre-mixed slurry, you will produce the moulds or cores. In certain circumstances, the slurry will be used to form a shell, which will be backed up using conventional mould forming materials. You will follow the laid-down procedure for the stripping times of the moulds or cores and for the subsequent treatments that will be performed on the products. You will also be expected to carry out any necessary repairs to the moulds or cores and to apply any required coatings/dressings. Your responsibilities will require you to comply with organisational policy and procedures for the ceramic mould or coremaking activities undertaken and to report any problems with the patterns or core boxes, slurry or equipment in use that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with minimal supervision, taking personal responsibility for your actions and for the quality and accuracy of the moulds or cores that you produce. Your underpinning knowledge will be sufficient to provide a sound basis for your work and will enable you to adopt an informed approach to applying ceramic mould or coremaking techniques. You will have an understanding of the different types of refractories in use and the additives and additions used in preparing the slurry you use to make the moulds or cores. You will also understand the different types of pattern or core box and associated accessories used, and their application, in adequate depth to provide a sound background for carrying out the activities to the required specification. Your knowledge will be sufficient to enable you to identify sub-standard slurry, patterns, core boxes, equipment and finished moulds or cores. You will understand the safety precautions required when carrying out the ceramic moulding or coremaking activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety, and the importance of taking the necessary safeguards to protect yourself and others in the workplace. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines 2. follow the correct component drawing or any other related specifications for the component to be produced 3. obtain and prepare the appropriate tools, equipment and materials 4. carry out the moulding or laying-up activities using the correct methods and techniques 5. produce components to the required specification 6. check that all the required operations have been completed and components are to specification 7. deal promptly and effectively with problems within your control and report those that cannot be solved 8. ensure that work records are completed, stored securely and available to others, as per organisational requirements 9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. how to obtain the job instructions and how to interpret their information 6. the different types of pattern or core boxes used in the ceramic moulding /coremaking process (plated patterns, solid turnout and split core boxes) 7. the different types of pattern or core box clamping devices used 8. the different types of moulding box/frames that are used 9. how the pattern or core box type can determine the production process 10. the different types of inserts that are used and their uses and limitations 11. the different ceramic moulding processes used (Shaw, Unicast) 12. the additions and additives that are used when mixing slurry, and how these affect the moulding/coremaking process 13. the type and application of mould or core coatings/dressings for different metal alloys 14. how to identify mould or core defects (soft spots, broken/damaged mould or core surfaces, and clagging/sticking or distorted sections) 15. the organisational quality control procedures for producing and inspecting the moulds or cores (cleanliness, completeness, freedom from foreign bodies and defects) 16. to the importance of keeping the patterns or core boxes and equipment clean and free from damage, good housekeeping of mould or core moulding tools and equipment and maintaining a clean working area 17. the extent of your own authority and whom you should report to if you have problems that you cannot resolve when making the ceramic moulds or cores 18. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Produce moulds or cores , carrying out all of the following activities: 1. confirm that all the required materials and equipment are available and are in a safe and usable condition 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. comply with job instructions and moulding or coremaking specifications 4. use the correct tools and equipment for the ceramic moulding/coremaking activity 5. follow the defined moulding/coremaking procedures 6. ensure that the moulds or cores produced meet the required specification for quality and accuracy 7. leave the work area in a safe condition on completion of the moulding/coremaking activities 2. Prepare the patterns or core boxes for use, to include both of the following: 1. visually inspecting the pattern or core box for damage 2. applying release agents to the pattern or core box (as applicable) 3. Obtain or mix the slurry using one of the following: 1. batch mixer 2. continuous mixer 4. Produce moulds, full cores or half cores from one of the following: 1. plated patterns 2. loose patterns 3. solid turnout and split core boxes 5. Produce moulds or cores which are backed up with conventional refractory material, using two of the following techniques: 1. hand tucking and ramming 2. inserting preformed sections 3. mechanical assistance with mould or core consolidation 6. Produce moulds or cores using one of the following processes: 1. Shaw 2. Unicast 3. other method (specify) 7. Apply mould or core coatings/dressings, using one of the following methods: 1. spray 2. flood 3. brush 4. dry 8. Check ceramic moulds or cores meet all of the following quality and accuracy standards: 1. complete and free from obvious defects (soft spots, cracks, broken or damaged surfaces) 2. required specification (shape, dimensional accuracy) 9. Sort the finished moulds or cores, placing them into the appropriate designated areas for either: 1. acceptable moulds/cores 2. disposal of sub-standard moulds /cores |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
31 Mar 2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.08
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; ceramic; moulds; cores; Shaw process; Unicast process